What cut-off wheel do I use for cutting metal?

Use a thin metal cut-off wheel (Type 1, 0.045-inch thick) for clean cuts in steel and stainless. Never use a masonry or concrete wheel on metal.

Can I cut aluminum with an angle grinder?

Yes, but use a wheel specifically rated for aluminum or non-ferrous metals. Standard steel cut-off wheels can load up with aluminum and become dangerous.

How do I prevent sparks when cutting metal?

Sparks are unavoidable with abrasive cut-off wheels on steel. Protect nearby surfaces, wear safety glasses and a face shield, and keep a fire extinguisher accessible.

How to Cut Metal with an Angle Grinder

An angle grinder with the right cut-off wheel is the fastest way to cut metal with an angle grinder on any job site. When you cut metal angle grinder wheel selection is the critical first decision. This guide covers wheel selection, safety, and technique for clean cuts in steel, stainless, aluminum, and pipe when you need to cut metal with an angle grinder.

Wheel Selection: How to Cut Metal with an Angle Grinder

For Steel and Carbon Steel

Use a standard aluminum oxide abrasive cut-off wheel, Type 27 (depressed center), 0.045” thick. This is the most common configuration — available at every hardware store. Thin wheels (0.045”) cut faster and generate less heat than thicker wheels.

For Stainless Steel

Use a wheel labeled “stainless” or “INOX.” Standard metal wheels contain iron, sulfur, and chlorine that contaminate stainless surfaces and cause rust. Stainless-rated wheels use a contaminant-free abrasive formulation.

For Aluminum

Use a wheel specifically rated for non-ferrous metals or aluminum. Standard metal wheels load up (clog) with aluminum and become dangerous. Aluminum-rated wheels have a different bond formulation that prevents loading.

For more on wheel types and ratings, see our Cut-Off Wheel Buying Guide.

Safety When You Cut Metal with an Angle Grinder

Eye protection is mandatory — metal cutting produces sparks and hot fragments that travel at high speed. Wear safety glasses minimum; a full-face shield is better.

Check the RPM rating. Every wheel has a maximum RPM printed on it. Your grinder’s speed must not exceed this number. See the RPM discussion in our Cut-Off Wheel Buying Guide.

No side pressure. Cut-off wheels are designed for plunge cuts only. Applying lateral force can crack or shatter the wheel. If you need to grind or deburr, switch to a grinding disc.

Secure the workpiece. Metal that moves during cutting can bind the wheel, causing kickback. Clamp or vise the material before cutting.

Technique: How to Cut Metal with an Angle Grinder Cleanly

Let the wheel do the work. Moderate pressure, steady pace. Forcing the wheel generates excess heat, wears the wheel faster, and produces a rougher cut.

Mark your cut line. Use a soapstone marker or scribe line for straight cuts. A straightedge clamped to the material helps guide long cuts.

Cut from the waste side. Position the blade so the waste piece falls away freely after the cut. This prevents the cut from closing on the blade and binding.

For concrete cutting with grinders Once you know how to cut metal angle grinder work becomes fast and routine., see How to Cut Concrete with an Angle Grinder. For concrete-specific wheels, see Best Cut-Off Wheels for Concrete.

Recommended Cut-Off Wheels

Metal cutting uses abrasive wheels, not diamond — so VA diamond blades aren’t the right product here. For metal cut-off wheels, look for Norton, DeWalt, or Diablo abrasive wheels on Amazon rated for your specific metal type (steel, stainless, aluminum).

If you also cut concrete with the same grinder, the VA 9-inch Ultra Value is the diamond blade to keep in your truck.

Browse Virginia Abrasives on Amazon →